Multi-Stage Cold Forging Process for Manufacturing a High-Strength One-Body Input Shaft

Jo, Ara; Jeong, Myeong Sik; Lee, Sang-Kon; Moon, Young Hoon; Hwang, Sun Kwang

doi:10.3390/ma14030532

Cited by 19 publications

(7 citation statements)

References 28 publications

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“…However, when considering the operating environment of the drive shaft, it has to satisfy a basic series of critical requirements such as sufficient structural stiffness and mechanical strength against torque, substantial durability, and so forth. To this end, the residual stress and the plastic deformation damage within the preform as the intermediate workpiece of the drive shaft have to be managed at an appropriate level [ 28 , 29 , 30 , 31 , 32 ].…”

Section: Introductionmentioning

confidence: 99%

Numerical and Experimental Investigations on Residual Stress and Hardness within a Cold Forward Extruded Preform

2023

Materials

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Using a preform fabricated by a cold forward extrusion process, the present study numerically predicted and experimentally investigated its residual stress and microstructural characteristics, as well as its plastic deformation damage and hardness. Prior to realizing the preform, AISI 1035 cold-drawn medium carbon steel material with a diameter of 50.0 mm and a height of 121.0 mm is first spheroidized and annealed, after which phosphophyllite is used to coat its outer surface. To identify the influence of the spheroidizing and annealing on the mechanical properties and the microstructural phase, uniaxial compression tests and microscopic observations are carried out. After assuming the deformation behavior of the workpiece during the cold forward extrusion with a plastic material model and with an elasto-plastic material model, separately, three-dimensional finite element simulations are adopted to visualize the residual stress and the plastic deformation damage. The preform produced by cold forward extrusion is fully scanned by using an optical 3D scanner, the Vickers micro-hardness is measured, and the residual stress through EBSD (electron backscatter diffraction) analysis is observed. Briefly, the results show that the ferrite and pearlite within the raw workpiece is well spheroidized by the heat treatment, and that there is a decrease in the KAM (kernel average misorientation) value of about 40%. In terms of the preform obtained by the cold forward extrusion, the dimensional requirement is more suitably met with the predicted layout when adopting the elasto-plastic material model than that of the plastic material one, and the numerically predicted residual stress agrees with the Vickers micro-hardness distribution. It can be verified that the dislocation density (or the internally stored strain energy) based on the IQ map and the IPF map is substantially increased around the extrusion region, and that the KAM value is increased by roughly 516% as the whole average of the observed values.

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Section: Introductionmentioning

confidence: 99%

Numerical and Experimental Investigations on Residual Stress and Hardness within a Cold Forward Extruded Preform

2023

Materials

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“…Winiarski et al [19] applied DEFORM 2D/3D to study, numerically, a six-stage cold forging process on the 42CrMo4 steel hollow flanged part to determine whether the proposed forging technique could be used to produce flanged hollow parts. A multi-stage cold-forming process applying finite element analysis was developed by Jo et al [20] to fabricate a high-strength one-body input shaft with a long body without separate parts. This study demonstrated the design and development of a multi-stage cold-forming process to fabricate a one-body input shaft with better mechanical properties and material recovery.…”

Section: Introductionmentioning

confidence: 99%

The Study of Multi-Stage Cold Forming Process for the Manufacture of Relief Valve Regulating Nuts

Yang

Liu

2023

Applied Sciences

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Cold forging is widely used in many industries. Multi-stage cold forming is usually utilized in forging fasteners. In this study, numerical simulation and experimental investigations were carried out on a five-stage cold-forming process for the manufacturing of low-carbon steel AISI 1010 relief valve regulating nuts. The forming process through five stages included preparation and centering for backward extrusion, backward extrusion over die pin, upset, backward extrusion over moving punch, and piercing. The formability of the workpiece was studied, such as the effects on forming force response, maximum forming force, effective stress and effective strain distributions, metal flow patterns, and strength. A comparison of the forming forces obtained in the forming experiment with the numerical simulation results of the five-stage cold forming showed a good agreement with the trend of the forming force growth. For the maximum forming force and forming energy, the fourth stage of backward extrusion over the moving punch at the upper face was the largest among the five stages. The total maximum forming forces from the first to the fifth stages were numerically 440.9 kN and experimentally 449.4 kN, meaning the FE simulation and experimental results were in good agreement. The numerically simulated effective strain distributions were consistent with the experimentally tested hardness distributions. Highly compacted grain flow lines also resulted in higher hardness. The overall hardness of the workpiece formed by five-stage cold forming increased by 31% compared to the initial billet. The hardness of the workpiece increased with the forming stages, and the strain-hardening effect was obvious. The strength of the workpiece was significantly increased by five-stage cold forming.

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“…Cold forging is an advanced manufacturing technique that is inexpensive and is widely used in the mass production of industrial parts, such as stepped shafts [1,2] and complex gears [3,4]. Although cold forging has developed considerably over the course of more than 70 years, shortening the process chain [5], reducing the number of process steps [6], and developing hybrid raw parts [7] remain areas that warrant further research.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of dry-in-place lubricants for cold forging by using an optimal steady combined forward and backward extrusion testing method

Osaki²,

Cai

et al. 2023

Friction

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This study evaluated dry-in-place lubricants used for cold forging. A group of isothermal compression tests with a strain rate ($$\dot \varepsilon $$ ε ˙ ) range of 0.001–1 s−1 and temperature (T) range of 30–400 °C were completed. The flow stress (σ) curves of annealed steel S45C were obtained, and a corresponding Hensel—Spittel model was developed to support finite element (FE) simulation. The sensitivity of the steady combined forward and backward extrusion (SCFBE) test proposed in another study was improved by approximately 20% after it was optimized using the results of the FE simulations. Key parameters were identified, and the calibration curves after optimization were obtained. On the basis of the optimized test, a friction testing setup with a heating system was developed, in which the die temperature could be adjusted from room temperature (RT) to 230 °C. Three dry-in-place lubricants and conventional phosphating lubricant were tested, and the friction factors (m), forming loads, and ejection loads were measured. The surface features of the specimens after testing were also investigated. According to the testing results, of the three tested dry-in-place lubricants, the mica type was the best. In addition, the optimized friction testing design was verified as effective.

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Multi-Stage Cold Forging Process for Manufacturing a High-Strength One-Body Input Shaft

Cited by 19 publications

References 28 publications

Numerical and Experimental Investigations on Residual Stress and Hardness within a Cold Forward Extruded Preform

Numerical and Experimental Investigations on Residual Stress and Hardness within a Cold Forward Extruded Preform

The Study of Multi-Stage Cold Forming Process for the Manufacture of Relief Valve Regulating Nuts

Evaluation of dry-in-place lubricants for cold forging by using an optimal steady combined forward and backward extrusion testing method

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